Inspection plug removal on 4 speed trans

[Ted K.]

Can't get the plug off the side of the 4 speed transmission to check the fluid level. It has apparently been stuck for a long time since most of it was rounded off before I started on it. I tried vice grips, plumbers monkey wrench, everything in my tool box. There is very little left of the plug to get a grip on. Is there any other way to check te fluid level? There is also no drain plug on this trans. I am assuming this has been like this a long time therefore I need to find a way to check the gear oil level.
Thanks,
Ted

[Joe L.]

Re: Inspection plug removal on 4 speed trans

Can't get the plug off the side of the 4 speed transmission to check the fluid level. It has apparently been stuck for a long time since most of it was rounded off before I started on it. I tried vice grips, plumbers monkey wrench, everything in my tool box. There is very little left of the plug to get a grip on. Is there any other way to check te fluid level? There is also no drain plug on this trans. I am assuming this has been like this a long time therefore I need to find a way to check the gear oil level.
Thanks,
Ted

Ted-----


This is a somewhat common problem. I had it happen to me once-upon-a-time. For some reason, the steel/cast iron plugs seize to the aluminum case and getting them out the normal way becomes impossible. I have found that even the repeated application of agents like AeroKroil won't do a thing. In your case, it's moot anyway because the head of the plug is gone.

What you can do as a temporary fix is to grind flat the head of the plug. Then, centerpunch and drill and tap for a 1/8" NPT pipe plug. Be as careful as possible to avoid the chips getting inside the transmission. Do this by drilling short depths and removing the chips each time. You will probably get a few chips into the transmission when you drill the final short depth. However, these will be caught by the magnet in the bottom of the transmission (when you do finally disassemble the transmission someday you're going to be surprised how much metal chips and fine metal "sludge" are attached to the magnet). You will need a compact right angle drill to do this drilling. Use grease on the tap to help hold the chips.

The small hole will allow you to check the level using a hand fabricated "dip-stick" and you'll also be able to add fluid if necessary.

Someday, when the trans is rebuilt (and the case empty), the permanent fix will be drilling out the plug using increasingly larger bits until the remaining plug is "paper thin". Then, remove the remnants with a sharp awl. By the way, the permanent fix needs to have a precise center. So, that's why you need to make sure you locate and drill on the precise center for the temporary fix.

[Ted K.]

Re: Inspection plug removal on 4 speed trans

Thanks. I was afraid that drilling and tapping was going to be the solution

[Bill H.]

Re: Inspection plug removal on 4 speed trans

After you have the first drill hole started, but not the whole way thru, put some grease on the drill bit. Most of the chips will get stuck in the grease.

[Domenic T.]

Re: Inspection plug removal on 4 speed trans

Ted,
If you remove the speedo gear housing you can blow compressed air into the trans and it will also blow air out the front, and with all the above advice you can blow the chips out as you drill & tap.

The danger would be if your trans was overfilled and you get oil on the clutch when the air is blown into the trans.

If you don't go all the way and have to do what Joe suggested with a dipstick remember that the trans level is NOT even with the hole and should be 1/2 in below the hole (cold) or you will throw oil out the front when you apply the brakes.

Some transmissions don't have a magnet on the bottom but the chance of soft cast iron doing damage to hardened gears and bearings is almost impossible.

I find lots of chips( hard and soft) in the transmissions when I tear them apart that were there a long long time and see no damage they cause other than large gear pieces.

The only softer parts inside are the brass syncro rings and 2 spacer washers and most likely they wouldn't see the chips before the hard parts eat them.

DOM